Frequency-aware decomposition learning for sensorless wrench estimation in vibration-rich robotic contact

Abstract

Force and torque (F/T) sensors enable contact-aware control by providing reactive feedback, but they are often fragile and expensive. To overcome these limitations, sensorless methods estimate F/T or wrench solely from robot proprioception, and have shown success in slow interaction tasks such as grasping. However, their low-pass characteristics limit the estimation of high-frequency signals, which are critical in rapid-contact tasks such as grinding. Communication delays can also make their estimates outdated during deployment, but few methods address this directly. To bridge these gaps, we propose a Frequency-aware Decomposition Network (FDN) to estimate vibration-rich wrench in a sensorless, multi-step-ahead manner. Considering higher-frequency stochasticity, FDN spectrally decomposes the wrench horizon into a low-frequency trend and a high-frequency residual, and estimates each by pointwise regression and a learned conditional distribution, respectively. The frequency-aware layers impose band decomposition priors on the outputs and adaptively enhance frequency amplitudes of the inputs. FDN requires neither an identified robot model nor an F/T sensor during estimation. On real-world grinding data from our 6-DoF hydraulic manipulator, FDN reduces high-frequency amplitude error by up to 47% over the baselines under assumed time delays and maintains competitive low-frequency pointwise accuracy, while the baselines fail to balance these two. We also find multi-step-ahead estimation feasible, with FDN estimating a 1,000 ms horizon within 11 ms on a single CPU thread. Ablation studies further support our design choices. In an exploratory study, transferring wrench dynamics learned from an open-source everyday manipulation dataset reduces low-frequency error by 8%, while high-frequency dynamics appear domain-specific.